Vacuum packaged food products and methods of making same

ABSTRACT

A packaged food article, comprising a package maintaining at least a partial vacuum and having at least a portion being flexible; and at least one food piece disposed therein in the form of a shaped solid composite mass comprising an aggregate base having a quantity of food particles, wherein at least a portion of the food piece is in conforming contact with the flexible package portion and wherein the food piece has a water activity of 0.45 or less is disclosed. In one embodiment the packaged food article further comprises binder. In most embodiments, the binder comprises 25% or less, by weight, of the product, resulting in a product that is less sweet than other grain-based handheld food products, yet retains a chewy texture. In another embodiment, highly oxygen sensitive ingredients are used as a food ingredient. The resulting product has a very long shelf life, maintaining its full color, texture and flavor for at least 3 months, up to about 12 months. Additionally, most of the frangible ingredients remain whole and there is minimal, if any, waste during manufacturing as no trimming is required.

FIELD

[0001] This invention relates to food products, and, in particular, thisinvention relates to vacuum packaged food products and methods of makingsame.

BACKGROUND

[0002] Ready-To-Eat (RTE) cereals are popular food products typicallyconsumed with milk. For added convenience, there have been many effortsin the food industry to develop portable ready-to-eat cereal foodproducts in bar form. Many such bar products are currently commerciallyavailable, such as the familiar granola bar. Such products aredistinguished from cookies, dessert bars or like products by absence ofa flour-based batter as a structuring agent and are not typicallyprepared by baking or other finish cooking step. Rather, a loose mixtureof RTE cereal particles is admixed with a high proportion of a sugarsyrup binder. The admixture is then pressed into slabs, cut intoindividually sized and shaped pieces and packaged.

[0003] While convenient and useful, such cereal bar products can sufferfrom one or more consumer complaints. Foremost, conventional cereal barproducts can be too sweet in taste for some adult consumers. Theexcessive sweetness is due to the need to employ high proportions of thesugar syrup binder needed to provide a product that is a solid masssuitable for forming into a shaped form that retains its shape, e.g.,bar or square that retains its form. For certain nutrition consciousconsumers, e.g., diabetics, high sugar(s) content is also undesirable.

[0004] Of course, efforts have been made to provide products in shapedform, such as bars that comprise puffed cereal pieces with lesserquantities of sugar slurry binder. However, as the amount of sugar syrupor slurry binder is reduced, the formulations, after cooling to set thebinder, become progressively a mixture of softer or more loosely boundparticles until forming a mere quantity of loosely bound particulatesrather than a solid mass.

[0005] Still another approach to providing a shaped food product havingenough binder to provide a solid mass, but with reduced sweetness, is tosubstitute a portion of the more sweet binding sugars with less sweetcarbohydrates equivalents, such as maltose sugars and/or maltodextrins.However, while binders comprising sugar replacements are less sweet,such products can exhibit other undesirable attributes. For example,products comprising high levels of maltodextrin as a binder constituentcan be quite hard and glassy in texture. Also, even though the productsare firm and less sweet, they can be objectionable as being too high insugars and too low in the cereal component.

[0006] Yet another technique for providing shaped or bar products ofreduced binder levels is to use compression or compaction to force theparticulates closer together. While the mixture of cereal and binder isstill warm and soft, a mass of cereal base and binder can be pressed bycompression rollers to form sheets. These sheets are allowed to cool andharden and are then slit into suitably sized pieces such as by cuttinglongitudinally into ribbons and then transversely into individualpieces.

[0007] While useful for modest reductions in binder, such techniques(especially when a puffed or otherwise frangible cereal base isemployed) can result in high percentages of product that are brokenand/or crushed or deformed. Products with so few, if any, remainingwhole cereal pieces suffer from another consumer complaint regardingappearance. Furthermore, the cutting step results in relatively sharpedges or surfaces. Such products further have flat top and bottomsurfaces due to the compression step, which, together with the sharpedges, impart a harsh and undesirably mechanical appearance aspect tothe products, which is another visual or appearance complaint fromconsumers.

[0008] Still another consumer complaint is that such products are toohard or tough in texture. While softer products, e.g., soft and chewygranola bars, are well known, such products are either sticky due torequired sugars formulation and amount of binder or otherwise requireuse of a “non-natural” humectant ingredient, such as glycerol or otherpolyhydric alcohol. Compaction (described above) can also aggravate thetough or heard eating quality.

[0009] These problems are difficult to overcome with unexpanded cerealproducts, such as granola bars, comprising unpuffed oat flakes orsimilar type products comprising slightly puffed cereal flakes such ascorn or wheat flakes (e.g., Golden Grahams® bars). These problems areeven more severe for products comprising puffed pieces such as wholegrain oat “O” Cheerios® pieces or puffed spheres e.g., Kix® puffed cornpieces. Not only are such puffed shapes more fragile and more easilyprone to damage, but also the individual pieces are larger and are morerounded.

[0010] In still other variations, a higher moisture binder is employedto form sheets or pieces of the particulates. These forms can then bebaked or dried to remove the excess water to form bars or pieces. Again,while useful, such baking or drying steps can require extra equipmentand steps to practice product preparation and can also adversely affectheat sensitive additives such as dried fruits or chocolate chips.

[0011] Another taste and appearance complaint is that while such currentcereal bar products often contain dried fruit pieces, such as raisins,the dried fruit lack taste and appearance appeal. There have also beenseveral attempts to include highly oxygen sensitive ingredients, such asfreeze-dried fruits, in these products. However, such products rapidlylose their quality upon oxygen exposure.

[0012] Thus, there is a continuing need for new and improved portablefood products that have an acceptable sweetness level, contain primarilyunbroken pieces, and have an adequate shelf life.

SUMMARY

[0013] A packaged food article, comprising a package maintaining atleast a partial vacuum, wherein at least a portion of the package isflexible; and at least one food piece disposed therein in the form of ashaped solid composite mass comprising an aggregate base having aquantity of food particles, wherein at least a portion of the food pieceis in conforming contact with the flexible package portion and whereinthe food piece has a water activity of 0.45 or less is disclosed. In oneembodiment the packaged food article further comprises binder.

[0014] The shaped formed food product piece is useful as a component orintermediate for a packaged food product. In a particular embodiment,the low water activity binder is a sugar syrup. In most embodiments, thedry ingredients or “base” to low water activity binder ratio is at least2:1

[0015] resulting in a finished product that is less sweet than othergrain-based handheld food products, yet retains a shaped configurationuntil at least immediately prior to consumption. In another embodiment,the products comprise highly oxygen sensitive ingredients, such asfruits or dried fruits that retain high levels of oxygen sensitiveflavor and/or color constituents for improved appearance and flavorwithout need of flavor and/or color enhancers.

[0016] The present invention also provides improvements in the vacuumpackaged cereal products and methods of preparation that are describedin commonly assigned co-pending U.S. Ser. No. 09/945,318, entitled“PACKAGE AND METHOD” (filed Aug. 31, 2001 by Knigge et al.), which isincorporated herein by reference. The present invention providesimprovements in that it has now been found that vacuum packaging findsparticular suitability for provision of formed cereal bar products ofreduced binder levels to provide hand held cereal bars in contrast tothe loose RTE cereals of the prior application. Also, the presentinvention contemplates the inclusion of highly oxygen sensitive cerealbar ingredients such as freeze dried fruit pieces.

[0017] Surprisingly, it has been found that such superior food productscan be formulated and fabricated by methods of preparation that employvacuum packaging to maintain bar integrity allowing for reducing, ifdesired, the levels of sugar syrup binder and that do not involvecompaction, baking or cutting steps. Additionally, the vacuum packagingmethods described herein can also be used for conventional foodproducts, such as food products not having reduced levels of binder,thus eliminating steps previously thought to be essential in producingsuch products, e.g., depositing, forming, cooling, slitting, dividing,and so forth. Vacuum packaging also provides for greater freshness notonly for whole grain ingredients but also especially for highly oxygensensitive ingredients such as freeze dried fruit ingredients.

[0018] In one embodiment, the present invention provides a method offorming a vacuum packaged food product comprising preparing a workablecomposite mass containing a grain-based food ingredient and a low wateractivity binder and placing a quantity of the workable composite massinto a flexible packaging envelope. The process continues by applying avacuum to the flexible packaging envelope and sealing the flexiblepackaging envelope to form a flexible sealed package. The processconcludes by allowing the workable composite mass to cure within theflexible sealed package to form a vacuum packaged food product. Theproduct can further be subdivided into desired portions prior topackaging. There is minimal product waste in the process of the presentinvention, as there is no trimming step required.

[0019] The present invention provides improvements in cereal barproducts that address one or all of the consumer complaints noted above,by providing cereal bar products with lower sugar content and sweetness,high levels of intact cereal pieces, improved overall more “natural”appearance, and a texture that is not tough. The products can have afresher flavor and appearance through extended room temperature storage.The resulting product has a very long shelf life, maintaining its fullcolor, texture and flavor for at least 3 months, up to about 12 months,even in variations comprising oxygen highly sensitive ingredients suchas freeze dried fruit.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020]FIG. 1 is a schematic drawing of a vacuum packaged food productcontaining a cured food piece in one embodiment of the presentinvention.

[0021]FIG. 2A is a schematic drawing of the cured food piece of FIG. 1after being removed from the package in one embodiment of the presentinvention.

[0022]FIG. 2B is a schematic drawing of an uncured food piece in oneembodiment of the present invention.

[0023]FIG. 3A is a simplified schematic drawing of a process forproducing the uncured food piece of FIG. 2B in one embodiment of thepresent invention.

[0024]FIG. 3B is a simplified schematic drawing of a process for vacuumpackaging the uncured food piece of FIG. 3A in one embodiment of thepresent invention.

[0025]FIG. 4 is a block diagram of the process for making the vacuumpackaged food product in one embodiment of the present invention.

DETAILED DESCRIPTION

[0026] In the following detailed description, reference is made to theaccompanying drawings that form a part hereof, and in which is shown byway of illustration, specific embodiments in which the invention can bepracticed. These embodiments are described in sufficient detail toenable those skilled in the art to practice the invention, and it is tobe understood that other embodiments can be utilized. It is also to beunderstood that structural, procedural and system changes can be madewithout departing from the spirit and scope of the present invention.The following detailed description is, therefore, not to be taken in alimiting sense, and the scope of the present invention is defined by theappended claims and their equivalents.

[0027] Various terms used throughout the description are defined first,followed by a discussion of various vacuum packagable food productembodiments, including information on their compositions. The processfor making the vacuum packaged food products is described next, followedby a brief conclusion highlighting some of the advantages of the variousembodiments of the invention.

[0028] Introductory Definitions

[0029] As used herein, the term “additive” is intended to encompass anytype of food ingredient added to the food product at any time duringmanufacturing. A “topping” is one type of additive which typically stayson “top” of the end product, although a “topping” can also be applied asa “coating” such that it adheres to some or all of the end product, withor without the assistance of a carrier substance. Liquids in any formare also considered to be additives. Embodiments that discuss the use of“toppings” can also include the use of any type of “additive.” Additivesalso include non-nutritive (non-carbohydrate) high potency sweeteners(such as aspartame, acesulfame K, Sucralose and saccharin) as well ascarbohydrate-based sweeteners, and any other “carbohydrate” as definedbelow. Additives further include acids, bases, salts, buffering systems,chelating agents, antioxidants, antimicrobial agents, gases/propellants,and so forth. Additives further include nutrient and health additivessuch as vitamins, minerals, encapsulated biologically active components,nutraceuticals (defined below), dietary supplements, anti-oxidants,fibers, inulin, calcium carbonate, probiotic bacteria sprinkles (e.g.,lactobacillus or acidophilus), energy additives, protein powders,powdered milk fractions, protein or satiety additives, herbs, aromaticsubstances, and other similar health-enhancing additives.

[0030] The term “nutraceutical” as used herein refers to ediblematerials having, or believed to have, medicinal effects. Nutraceuticalsinclude the, ginseng and other herbs, St. John's Wort, wheat grass andbarley grass and extracts of the grasses, soy-based estrogen analogs(isoflavones). Nutraceuticals can also be a source of vitamins, e.g.,tocopherols, B vitamins and minerals and so on.

[0031] The term “color” or “coloring agent” as used herein refers tonatural or uncertified colors from natural sources or certified colorsfor the effect of color. In one embodiment, the colors include dyes,certified aluminum laks or colors derived from a natural source.Coloring agents may also be water-based or oil-based or dry. Coloringagents may be primary colors, blends of colors or discrete mixtures ofcolors, such as confetti.

[0032] The term “compound coating” refers to a coating containing anyfat other than cocoa butter. This is unlike “chocolate” which mustcontain cocoa butter.

[0033] The term “density” when used without qualification herein refersto “bulk density” of a component or composition.

[0034] The term “fat” as used herein is synonymous with the term “lipid”and refers to substantially all fats and oils and fat substitutes,including any animal or vegetable fat in solid or liquid form.

[0035] The term “flavor” or “flavoring” as used herein refers to anorganoleptic agent in the form of an emulsion, concentrate, aqueous- oroil-soluble liquid or a dry powder, as well as any type of chunky pieceor pieces that may be added to a mixture at any time in the process.Flavorings can also be considered additives and can include nuts, nutpieces, fresh fruits, dried fruits, fruit products, candies,marshmallows, “marbits,” chocolates and chocolate products, and soforth. Flavorings further include any fruit flavors such as berryflavors, apple, cherry, plum, raisin, banana, pear, peach, figs, datesand so on. Flavorings may also include fats, salts, honeys, cheeses,frosting, powdered food products, sugar, sugar substitutes, gelatins andspices. Flavorings may also include colorings as well as any nut flavorsas well as any sweet flavors such as chocolate, vanilla, caramel,butterscotch, lemon, malt, cinnamon, graham, coconut flavors, mint andso on. Flavorings additionally include any savory flavors such as allmeat, game, fowl, fish, dairy, barbecue, smoke, pepper, spicy andvegetable flavors.

[0036] The term “light sensitive” refers to a food that reacts to thepresence of visible light, resulting in degradation in desirableattribute over a relatively short period of time such as loss of coloror flavor or development of an off flavor, e.g., rancidity. Some foodsthat are also “light sensitive” are also “oxygen sensitive,” such asvarious dairy products, fruit and dried fruit, especially freeze driedfruit. However, if the exposure to oxygen is reduced or eliminated, theflavor and/or color degradation resulting from sensitivity to light willbe minimized.

[0037] The term “oxygen sensitive” as used herein refers to a food thatoxidizes in the presence of air. Foods containing free fatty acids, suchas whole grains, for example, will react with any oxygen in the packageenvironment, leading to oxidation. The resulting product is a peroxide,which reacts to form an aldehyde, or more specifically, hexanal. Hexanalis a marker for rancidity, and at one (1) 1 ppm, rancidity is apparentto the average consumer. Other foods, such as fruits, also lose color orflavor in response to oxidation.

[0038] The term “highly oxygen sensitive” refers to oxygen sensitiveingredients that exhibit high rates of oxygen degradation or degradeeven in low oxygen environments. Fruits and freeze-dried fruitsespecially lightly colored, with the exception of raisins, are examplesof highly oxygen sensitive ingredients.

[0039] The term “aggregate” or “aggregate base” as used herein refers toa mixture of food pieces, i.e., particles (particulates). An aggregateis essentially a mixture of dry ingredients that can be held together(such as with a binder) to form a single food piece. An aggregate cancomprise large pieces, up to about 10 to 12 mm (0.4 to 0.5 in), and insome instances up to about 20 mm (0.8 in), as well as small pieces, downto about two (2) mm (0.08 in), further including powders of yet smallerdimensions as is known in the art. Such powders can include corn starchcomprised of particles having a size such that about 98% of theparticles, by weight, can pass through a 100-mesh US screen. Powders canfurther include, but are not limited to, cinnamon dust, a cinnamondust/sugar combination, maltodextrin, and the like. An aggregate can bea mixture of pieces having different sizes or can include pieces thatare all about the same size. However, an aggregate will typically notcontain more than about 20% of the particles in powder form. Anaggregate can include grain-based particles, such as RTE-cereals,popcorn, crackers, pretzels, grain-based chips, savory seasoned snacks,and the like, as well as non-grain based particles that include, but arenot limited to, dried whole fruits (e.g., raisins, dates, blueberries,peaches, raspberries, apricots, strawberries, cranberries, tropical[e.g., pineapple, papaya and mango], etc.), fruit parts (e.g., bananachips, apple chunks, etc.), dried fruit products (whether or not infusedwith sugar, glycerol, etc.), marshmallows, marshmallow bits (dried ormoist), malted milk balls, chocolate and peanut butter chunks, chocolate(e.g., milk chocolate, dark chocolate, white chocolate, etc.), chocolateproducts (e.g., chocolate-coated raisins, chocolate-coated peanuts,etc.), nuts (e.g., walnuts, raisin nuts, pecans, peanuts, almonds, hazelnuts, macadamia nuts, etc.), shredded coconut, yogurt chips (e.g.,vanilla, blueberry, strawberry), clusters of particulates (e.g., honeynut clusters), and so forth.

[0040] The term “cereal bar base” as used herein refers to one type of“aggregate base.” The primary base ingredient in the “cereal bar base”is typically a grain-based dry food ingredient. In most embodiments,this is a RTE cereal, sometimes referred to as the “parent cereal.” Insome instances, the primary base ingredient is the only type ofingredient in the base. In other embodiments, other types of grain-basedor non-grain based particles, as defined above, are also present in a“cereal bar base.”

[0041] Vacuum Packagable Food Product Embodiments

[0042] The basic physical composition of the vacuum packaged foodproduct is that of a solid conglomeration or single composite masscomprised of a major portion of an aggregate base and, in mostembodiments, a minor portion of a low water activity binder that can beformed into a desired shape and size using vacuum packaging. The packageitself can be characterized as an “active package” as opposed to a“passive package.” Specifically, the active package is designed tocontribute directly to the process of forming the final product bysupplying pressure and dynamic forces to an intermediate uncuredconglomeration. Essentially, the active package, over time, urges theconglomeration together. The conglomeration, in turn, progresses overtime from a warm and plastic deformable (uncured) mass to a cooled andcured or set final product.

[0043]FIG. 1 shows one embodiment of a vacuumed packaged food product 10comprising a food quantity or piece (hereinafter “cured food piece”) 100disposed within a package, such as the pouch 106 shown in FIG. 1. Thepouch 106 depicted is fabricated at least in part from a flexiblepackaging material such as a packaging film. The cured food piece 100comprises an aggregate base having one or more dry ingredients. In theembodiment shown in FIG. 1, the cured food piece 100 comprises two dryingredients, namely a first or primary “grain-based” base ingredient(hereinafter “primary base ingredient”) 102 and a second base ingredient104.

[0044] The packaging film can be any suitable material, but needs to besufficiently strong to contain the contents within and remain punctureresistant. The packaging film further needs to have a sufficiently lowoxygen permeability, be heat sealable and be able to maintain a vacuumover an extended shelf life. Useful packaging films are well known andthe skilled artisan will have no difficulty in selecting commerciallyavailable films for use herein.

[0045] The packaging film can be clear, translucent or opaque or haveportions that are clear. The exterior portion of the pouch 106 can alsobe textured, e.g., dimpled, if desired. In a particular embodiment, eachcured food piece 100 is individually “pouched” in an opaque flexiblemetallized film known in the art. In one embodiment, an opaque film ofthe type used for vacuum packaged coffee is used. Such films typicallyhave an additional inner or intermediate foil layer for added strength.In another embodiment, the clear materials can include materials such asa ceramic-coated polyester film. The advantage of using a clear materialis that it allows the consumer to view the product prior to opening,although a viewing window can be provided in other packaging materials.

[0046] In one embodiment, the pouch 106 is fabricated from packagingfilm that is a single layer formed of a film or a single sheet. Inanother embodiment, the pouch 106 is fabricated from other packagingfilm such as a laminate, a co-extrusion, or a combination thereof.Preferably, the packaging material is selected to be of low oxygenpermeability. Typical low oxygen permeable packaging materials have anoxygen permeability of no greater than about 0.31 cc/100 m²/24 hr. In afurther embodiment, the laminate has an oxygen permeability of nogreater than about 0.2 cc/100 m²/24 hr. The laminate can be a flexiblematerial comprising a polymer substrate selected from the groupconsisting of polyethylene (PE), polypropylene (PP), polyethyleneterephthalate (PET), and polylactic acid (PLA), an oxygen barrier layer,and a moisture barrier layer comprising a metallized polymericcomposite. The laminate can further comprise a film or ceramic includinga component selected from the group consisting of oxygen scavengers andantioxidants. In one embodiment, oxygen scavengers are incorporated intothe substrate, the oxygen scavengers being selected from the groupconsisting of light activated oxygen scavengers and conventional oxygenscavengers. In one embodiment, the laminate is a flexible materialcomprising a layer of aluminum oxide coated polyethylene, a layer ofpolyester, a layer of glass or ceramic, and a polyester sealant interiorof the aluminum oxide coated polyethylene layer. In a furtherembodiment, the laminate comprises a moisture barrier coating exteriorof an oxygen barrier coating.

[0047] In one embodiment, the pouch 106 can include a means forassisting or controlling the opening of the pouch 106, such as a scoringnotch 120. In another embodiment, the pouch 106 can include perforationsthat are torn apart to facilitate controlled opening of the pouch 106.In other embodiments, the pouch 106 can include any type of recloseableopening (not shown), which can be reclosed by adhesive, zipper, clip,tin tie, or the like. In still another variation (not shown), the pouch106 can be fabricated with a stand feature at one end to allow fordisplay in a vertical orientation without need for additional packaging,e.g., an exterior carton.

[0048] The vacuum packaged food product 110 is desirably free of anyadded controlled packaging headspace gas, such as any type of gas thatis added to the package after the vacuum has been applied. Such gasesinclude nitrogen, nitrous oxide, neon, argon or mixtures thereof tomaintain structure and an interior environment having less than aboutone (1) ppm hexanal. Such gases are not necessary in the presentinvention as the pouch 106 is form-fitting around the cured food piece100 and the contents are further sufficiently crush resistant and do notrequire added cushion.

[0049] Individual vacuum packaged food products 110 can be sold, such asin vending machines or convenience stores. If desired, any number ofindividually vacuum packaged food products 110 can be packaged in asecondary container or carton, e.g., four (4)-20 pouches, fordistribution or as consumer products. Use of vacuum packaging maximizesavailable space, both when the product is shipped and on store shelves.In one embodiment, a single vacuum packaged food product 110 is placedin an individual carton, such as for use in fast food restaurants,airplanes, and so forth. It is also possible to ship individual vacuumpackaged food products 110 without placing them in individual cartons.In a particular embodiment, small, regular or king-sized food productsare packaged for individually dispensing in a vending machine. In oneembodiment, six (6) vacuum packaged food products 110 are packagedtogether in a consumer-sized container that is smaller than a 6-pack ofconventional cereal bars. In another embodiment, less than six (6)vacuum packaged food products 110 are placed in a carton. In yet anotherembodiment, seven (7) to 12 vacuum packaged food products 110 or moreare placed in a carton. In one embodiment, the consumer-sized containeris about 2,000 to 5,000 cc and holds more than one vacuum packaged foodproduct 110. In another embodiment, a large slab of food product such asabout 25 cm by 35 cm (about ten (10) in by 14 in), is packaged in aflexible metallized film for use in a food service facility where it iscut into individual servings to be sold at a later time.

[0050] The pouch 106 can be preprinted with product information, or canfurther comprise a pressure sensitive label affixed to the exteriorportion of the pouch, the label providing product information, includingnutritional information. The label for the vacuum packagable foodproduct can further include a statement that each food product containsreduced binder amounts. The details on the nutritional content of thefood products can be presented both on the outside carton as well as oneach individually wrapped layered food product. In one embodiment (notshown), the pouch 106 includes a coupon or premium, which can be locatedor printed on or mounted upon the exterior portion, or alternatively canbe provided within the pouch 106. In another variation the pouch 106 caninclude a second separate compartment in which the coupon is located.

[0051]FIG. 2A depicts the cured food piece 100 after having been removedfrom the packaging film. As noted above, in the embodiments shown inFIGS. 1 and 2A, the cured food piece 100 comprises an aggregate basecontaining the primary base ingredient 102 and the second baseingredient 104. The primary base ingredient 102 is a particlecharacterized by a larger average particle size and the second baseingredient 104 is a particle characterized by a smaller average particlesize. Specifically, the second base ingredient 104, i.e., “smallerpieces,” nests within the interstices formed by a quantity of theprimary base ingredient 102, i.e., “larger pieces.” In most embodiments,the aggregate base is a cereal bar base having a primary base ingredient102 comprised of RTE cereal pieces. In certain variations the RTE cerealpieces have a more complex shape, such as the “O” or ring shaped piecesshown in FIGS. 1 and 2A, rather than the simpler, generally irregularlyrounded pieces comprising the second base ingredient 104. FIG. 2Afurther depicts that, in most embodiments, the cured food piece 100 isnot a “sheeted” product, and thus has no generally straight-cut or flatsurfaces. Rather, in a preferred form at least one surface is roundedand in more preferred embodiments all surfaces are rounded and notsheeted or flat and/or all edges or ends are rounded and uncut.

[0052] An additional advantage of combining larger, more fragile puffedRTE cereal pieces with the smaller nested dry ingredients is thatfinished bar products exhibit surprisingly greater crush strength whenvacuum packaged herein compared to like quantities of the puffed RTEcereal pieces without the nested dry ingredients.

[0053] The primary and second base ingredients, 102 and 104,respectively, can be combined in any suitable ratio. In one variation,the weight proportions of larger to smaller pieces are substantiallyequivalent, i.e., combined in a ratio of 1:1. In another embodiment, thetwo dry ingredients are combined in a weight ratio of larger sized tosmaller sized pieces in a weight ratio of about 2:1, 3:1, 4:1, and soforth. In other embodiments, the dry ingredients are combined in a ratioof from about 1:5 to 1:30. Similarly, in embodiments using more than twodry ingredients in the base, the ratios can be at any desired levels. Ina particular embodiment RTE cereal pieces and dried fruit pieces arecombined in a ratio of about 20:1.

[0054] As shown in both FIGS. 1 and 2A, the cured food piece 100 has asubstantially oblong shape. While the depicted piece is morerectangular, product shapes that are more cylindrical are alsocontemplated herein. However, as can be seen, the edges of the foodproduct are not straight, as none of the six surfaces have been straightor knife-cut. In an exemplary embodiment, the cured food piece 100 pieceweighs about 100 g and has a dimensions of about nine (9) to 13 cm(about 3.5 to five (5) in) long, about 3.2 to four (4) cm (about 1.25 to1.6 in) wide and about 0.9 to 3.2 cm (about 0.3 to 1.25 in) thick. FIG.2A is not necessarily drawn to scale and does not necessarily representthe actual density or thickness of the product, nor the actualproportion of the components in the cured food piece 100.

[0055] In another variation (not shown), the cured food piece 100 ismore square-shaped yet nonetheless has neither flat surfaces or cutedges. In another variation, the cured food piece 100 is substantiallyround or oval-shaped. In yet another shape variation, the cured foodpiece 100 is substantially ring-shaped with a hole of any suitablediameter in the center. One advantage of having a substantially “round”food piece and package, is that shelf space can be maximized. In anotherembodiment, the cured food piece 100 has a substantially log shape. Inyet another embodiment, the cured food piece 100 has an irregular shape,with a variable thickness, having the appearance of a slightly flattenedcomposite mass. Although cutting is not necessary, if desired, some orall of the surfaces can be cut to form any of the aforementioned shapesmore precisely.

[0056] In one less preferred embodiment, the cured food piece 100 is acut food product that is cut into bite-size pieces. Such a food productcan be any suitable shape, such as any type of simple or complex shape.This includes regular geometric shapes (e.g., squares, rounds,triangles, hexagonals, tubes, and so forth) and irregular shapes, whichcan be patterned (e.g., figurines, animals, trees, holiday shapes,stars, pillows, twists, wagon wheels, etc.) or unpatterned, such as anugget shape. Many of the geometric shapes, such as hexagonal, andvarious combinations of regular and irregular shapes (e.g., crab, palmtree and bird), can be interlocked together or “tessellated” such thatwhen cut, there is no web or waste left over.

[0057] As noted above, the “base” of the cured food piece 100 can, insome embodiments, comprise at least two dry ingredients, namely thelarger primary base ingredient 102, e.g., parent cereal, and the smallersecond base ingredient 104, such as dried fruit. In one embodiment, thesecond base ingredient 104 comprises more than one dry ingredient. A“dry” ingredient is a food ingredient having a water activity of lessthan about 0.4 and can range as low as about 0.1, such as for particulardried RTE cereal pieces. Such dry ingredients can includes bothfrangible food ingredients, such as RTE cereal pieces, and non frangibleingredients or products, e.g., dried fruit, nut pieces, chocolate chipsor other candies, etc.

[0058] The frangible food ingredient(s) can be selected from a widevariety of ingredients, including, but not limited to, puffed RTEcereals (e.g., spheres, 0-rings fabricated from dried cooked cerealdoughs, and the like), including puffed rice pieces, or unpuffed cerealpieces (e.g., shreds, flakes, biscuits, squares and mixtures thereof,etc.) as well as other grain-based unpuffed foods (e.g., chips,pretzels, crackers, etc.), further including protein pieces (e.g.,texturized vegetable protein (TVP) pieces) as well as flake grinds,nuts, nut pieces, granola pieces, nuggets, marshmallows, driedmarshmallow bits (marbits), candies, candy pieces, cookies, cookiepieces, chocolates and chocolate products, including white and milkchocolates (e.g., chocolate chips, candy bars, etc.), other types ofedible particulates (e.g., peanut butter chips, butterscotch chips,etc.), and the like, as well as “popped” foods such as popcorn. In mostembodiments, at least one of the dry ingredients is supplied by agrain-based food cooked cereal dough or oat flakes, although theinvention is not so limited.

[0059] The puffed pieces of cooked cereal dough can be prepared byconventional hot air or gun puffing to provide low fat cereal pieces asare generally used as RTE cereal products. In other less preferredvariations, all or a portion of the puffed cooked cereal dough piecescan be prepared by deep fat frying to provided fat containing puffedcereal pieces. The dried cooked cereal dough-based material can alsotake on any of a variety of shapes as noted above, including o-rings,flakes, shreds, biscuits, rings, spheres, squares, rounds, triangles,convex-shapes, hexagonals, tubes, cornucopia, oblongs, pillows, and soforth, including any other desired shape discussed above in relation tothe possible shapes for the food products themselves. The piecesthemselves can be as large or small as desired, provided the product canstill be produced with minimal or no breakage of the pieces. Very largepieces, such as those in excess of about seven (7) mm diameter, are moreeasily broken, and are not as practical in most embodiments. In apreferred embodiment, the cereal-based pieces have a mean particle sizeof about give (5) mm to about eight (8) mm.

[0060] In particular embodiments, the primary base ingredient 102 can beany known and popular RTE cereal, such as any type of Cheerios® (e.g.,regular Cheerios®, Apple Cinnamon Cheerios®, Honey Nut Cheerios®), anytype of Chex® (e.g., Honey Nut Chex®, Wheat Chex®, Rice Chex®, CornChex®, Bran Chex®), Cocoa Puffs®, Cinnamon Toast Crunch®, Oatmeal RaisinCrisp®, Wheaties®, Total®, Trix®^(,) Kix®, generic substitutes for theseand other RTE cereal products, various combinations of one or morecereal types, and so forth.

[0061] RTE cereal is an excellent source of many nutrients, includingcomplex carbohydrates, protein and fiber. In one embodiment, the cerealpieces used comprise about one (1) to two (2) g of declared fiber orabout 2.5% to about four (4)%, by weight, of the final product. In oneembodiment, the RTE cereal is modified to increase or decrease fiber orother ingredients. For example, additional raisins can be added as thesecondary base ingredient 104. In another embodiment, a sugar or otherflavored coating, i.e., slurry coating, is added to the outside of theRTE cereal. A sugar coating is used as a flavoring, but can also serveto improve shelf life and texture. In yet another embodiment, an“oat-predominant” (greater than 50% oats dry weight basis) cereal basecan be replaced with an “oat-containing” (less than 50% oats dry weightbasis) cereal base. An “oat-containing” formulation has known advantagesrelating to shelf life, since oats are known to lose freshness soonerthan other grains due to their lipid content. It is also possible tosubstitute or add any number of other grains into the cereal base,including rice, corn, sorghum, rye, wheat, barley, and so forth, in anysuitable ratio, depending on the particular application. In oneembodiment, the RTE cereal comprises about 20 to 25% by weight of thefood product.

[0062] In one embodiment, the base (either the primary and/or secondarybase ingredient, 102 and/or 104, respectively) is comprised of anygrain-based material, at least a portion of which comprises a wholegrain selected from the group consisting of whole grain oats, wholegrain rice, whole grain corn (maize), whole grain rye, whole grainwheat, and mixtures thereof. The grain-based material can furthercomprise soybean flour. In one embodiment, pretreated oat flour, as isknown in the art, is used in the grain-based material.

[0063] As noted above, another type of dry ingredient useful herein is acooked extruded high-protein and rice expanded or puffed pieces. Such aningredient can be used as either the primary base ingredient 102 and/orthe secondary base ingredient 104, as desired, and depending in largepart on size in relation to other ingredients present. Rice flour isadmixed with soy flour or soy protein flour to provide puffed proteinbearing pieces having a crispy texture that can be added to the otherdry ingredients. Further, since rice tastes relatively bland, there isno off-flavor to interfere with the flavor of the other dry ingredients.In one embodiment, the high-protein rice pieces are made byincorporating soy protein in extruded rice pieces at very high levels ofabout 50% or higher. In a particular embodiment, high-protein soy/ricepieces are obtained from Ringger Foods, Gridley, Ill. or Du Pont ProteinTechnologies International (PTI) in St. Louis, Mo. The soy/rice piecescan be any suitable size and shape. It is known that the size and shapeof the soy/rice pieces can vary depending on manufacturing conditions,machine die plates, formulation, and so forth. In one embodiment, thesoy/rice pieces have an elongated oval shape. In another embodiment, thepieces have a variety of diameters ranging from about two (2) mm toabout eight (8) mm. In embodiments in which this ingredient is used as asecondary base ingredient 104, the various sizes act as fillers betweenother, larger dry ingredients of the primary base ingredient 102. Thedensity of the pieces can also vary depending on the particular type ofpieces used, method of producing the pieces, and so forth. In oneembodiment, the bulk density of the soy/rice pieces range from about 10to 30 g/100 cc (about 175 to about 475 g/100 in²). In a particularembodiment, soy crisp rice pieces having a bulk density of about 15 to25 g/100 cc (about 300 to 400 g/100 in²) are used. In one embodiment,the soy/rice pieces comprise about one (1) to 12%, by weight, of thefinal product.

[0064] The second base ingredient 104 can, and in certain preferredembodiments does, include highly oxygen sensitive ingredients such asfruit and dried fruit, including freeze-dried fruit. Freeze drying isoften used to prepare high quality dried materials such as fruits thatexhibit higher levels of flavor, aroma and/or color resulting from thegentler dehydration that freeze drying provides. Freeze-dried fruitingredients are substantially more costly than other dried fruitingredients not only due to higher end product qualities but alsobecause of the cost and difficulty of the freeze-drying operationitself. An additional advantage of vacuum packaging is that the fresharoma of the ingredients are retained for at least 3 months, up to about12 months after packaging, thus enhancing the enjoyment of the foodproduct for an extensive period of time. This is particularly true forhighly oxygen sensitive ingredients, which retain a particularlynoticeable fresh food smell. Also, current consumer trends favorcereal-based products that contain dried strawberry, raspberry and/orcranberry pieces. As each of these popular dried fruit pieces areparticularly sensitive to oxygen degradation, the present inventionfinds particular suitability for use for those product executions thatcomprise on or more of these dried fruit ingredients. In still otherembodiments, the base can comprise pieces of dried fruit foams (see, forexample, U.S. Pat. No. 5,451,419 “DRIED FOOD FOAM PRODUCTS” issued Sept.19, 1995, commonly assigned and incorporated herein by reference).

[0065] In one embodiment, pieces of a single type of RTE cereal andhighly oxygen sensitive ingredient comprise the aggregate base as theprimary base ingredient 102 and secondary base ingredient 104,respectively. In a particular embodiment, the highly oxygen sensitiveingredient comprises about two (2) to 10%, by weight, of the foodproduct. In other embodiments, there are three or more dry ingredienttypes in the aggregate base, which can include other types of RTE cerealpieces and/or highly oxygen sensitive ingredients and/or a third type ofingredient, such as any of the dry ingredients noted above.

[0066] In a particular embodiment, the base can optionally furthercomprise grain-based puffed dried spherical dots or pellets about one(1) mm in diameter that add a crunchy texture to a slurry. When added toa fruit slurry, the resulting product can be referred to as a “crispyfruit.” See commonly assigned and co-pending U.S. Ser. No. 10/209,707,entitled “FOOD PRODUCT AND METHOD OF PREPARATION ” (filed Aug. 1, 2002byDean F. Funk et al), which is incorporated herein by reference. Suchproducts can additionally or alternatively be added into any filling ortopping that is present.

[0067] If desired, up to about 15% of the dry base ingredient can besupplied by cereal fines, i.e., smaller sized ground or broken particlesthat are an underutilized by-product of RTE cereal production. Anadvantage of the present invention is that such cereal fines can beadded to provide characterizing flavor and color as well as tofacilitate agglomeration of the composite mass into a food bar.

[0068] While the invention finds particular suitability for use toprovide RTE cereal and grain-based snack products in bar form comprisingpuffed pieces of cooked cereal doughs and comprising various RTE cerealand/or snack food added particulates such as dried fruits and nuts forhuman consumption, the invention can also be used to provide pet oranimal food products. Particularly for domestic companion animals suchas cats and dogs, the base pieces can comprise puffed grain based basepieces that include higher levels of meat and meat by products or othersources of protein. It will be appreciated that such products can alsobe fortified with or formulated to include fat and/or fiber sources toprovide complete animal rations. Such products generally will exhibitsubstantially higher product densities although equivalent wateractivity values within the ranges described herein. Likewise, barproducts for complete human field rations are contemplated herein.

[0069] The binder (not shown) adheres the dry ingredients together inthe food product and typically forms an intermittent essentiallyinvisible “skin” on the surface of the aggregate base. Binder sugarsyrup formulations are well known and the skilled artisan will have notdifficulty in selecting ingredients and preparing the low water activitybinder syrups useful herein. Generally, any type of food product havingsufficient tackiness at application temperatures to hold the individualingredients of the cereal bar base together can be used as the binder.Application temperatures can range from ambient temperature to about140° C., depending on many factors, including the consistency of thebinder at lower temperatures, as many binders are solids or stickypastes at room temperatures.

[0070] Due to the compression action of the vacuum packaging describedherein, as compared with previously employed passive atmosphericpackaging together with optional compression of the food product, it isnot necessary for the binder to possess any “minimum strength”sufficient to withstand the forces involved with compression, shippingand handling. As a result, the binders of the present invention can bemuch less complex in their formulations.

[0071] However, the water activity of the binder needs to be a levelsufficient to maintain product stability at room temperature. Wateractivity in the binder can be controlled by selection of different typesof sugars, humectants, and other low molecular weight ingredients, e.g.,salt. As a result, the water activity of the binder can range from about0.25 to 0.65. In one embodiment, the water activity is between about0.35 and 0.5. In a preferred embodiment, the binder has a water activityof no more than about 0.45.

[0072] In one embodiment, the binder is comprised of sugar syrupsprepared from various liquid sugar ingredients, including corn syrups,maltose syrups, and various dissolved dry ingredients sugars, (i.e.,fructose, sucrose, dextrose, trehalose, etc.), as well as minoringredients such as, humectants, including, but not limited topolyhydric alcohols (e.g., glycerin, sorbitol, xylitol, manitol andpropylene glycol), and other ingredients, such as salt, in amountssufficient to provide the desired water activity.

[0073] In one embodiment, between about 0.1 and eight (8)% of humectantsare used in the binder (and/or base). In addition to lowering wateractivity, humectants are known to impart a desirable “chewiness” to theproduct. In other embodiments less than about 0.5% humectants are addedto the binder (and/or base). In one embodiment, up to about eight (8)%glycerin is used. It is generally not practical to add higher amounts ofglycerin beyond about eight (8)%, since higher levels can cause throatirritation.

[0074] Preferred sugar syrup binders contain sucrose (20 to 80 weight%), 42 dextrose equivalent corn syrup (20 to 80 weight %), a humectant,such as glycerin (0 to 6 weight %, with a preferred range of about 3 to5 weight %) and water (0 to 5 weight %). In an exemplary embodiment thebinder has about 62% corn syrup, 4.5% glycerin, 2.5% water, with theremainder being sugar.

[0075] In yet another embodiment, the product is substantially free ofhumectants, such that it is considered an “all natural” food product.Such an embodiment is important to consumers desiring “all natural”products and/or who are sensitive to the flavors imparted to productscontaining even small quantities of these materials. Such flavors aredescribed by some as being bitter in nature. Furthermore, it is knownthat the addition of humectants, such as polyol materials, can soften,to various degrees, and adversely degrade the desirable crisp texture offrangible dry ingredients, particularly RTE cereal pieces.

[0076] In certain variations, all or a portion of the sugar(s) contentcan be substituted with fructo oligo saccharides (“FOS”) ingredientssuch as inulin to provide added soluble fiber benefits. Of particularinterest is inulin in view of its bland flavor and solubility. Ifpresent, inulin can comprise from about 0.1 to 50% of the coatingcomposition, preferably about 5 to 15%. If desired, other fructo oligosaccharides (“FOS”) can be used in full or partial substitution forinulin, especially short chain FOS (“scFOS”). The FOS materials canconveniently be added to the sugar syrup as either dried materials or inthe form of low moisture syrups.

[0077] In yet other embodiments, water is used as the binder. In anotherembodiment, a combination of water and corn starch is used as thebinder. Optionally, the sugar binder syrup or slurry can additionallycomprise an oil component or oil-bearing component such as peanutbutter. In one embodiment, a chocolate or cocoa butter bearing binder isused. Indeed, in less preferred but operable embodiments, peanut butteror other nut butters, especially those processed or hydrogenated to besolid at room temperatures, could be used alone as the binder.

[0078] Additionally, other binder-like ingredients of low water activity(i.e., 0.45 and lower) can also be used in like manner to nut butters inaddition to or instead of a conventional sugar solution binder, such ashoney, concentrated consommes, soft or processed cheeses, fruit pastesor syrups, meat pastes, and the like. In one embodiment the binderingredient includes isomalt, a low calorie nutritive sweetener. Often,such binder ingredients will include various levels of sugars, saltsand/or humectants to lower water activity, but the invention is not solimited. In practice, such binders are combined with base ingredientswhile the binder is in an uncured or formable state (due to time and/ortemperature and/or other condition known in the art) and allowed tofinish curing after being packaged together with the base as describedherein. Essentially, once the binder cures, the composite masscomprising the binder and base is also considered to be cured or set.

[0079] In preferred embodiments, the binder additionally comprises aprotein binder ingredient for increasing the strength of the binder.Useful protein binder ingredients are well known and can include, forexample, gelatin, modified soy protein, milk caseinate and mixturesthereof. Preferred for use herein as the binder protein ingredient isgelatin, such as in a ratio of about 4:1 with hot water. Use of agelatin-containing binder with certain RTE cereals improves storagestability, as compared with a carbohydrate non-gelatin binder, byslowing moisture uptake, which can cause various textural defects in thedry ingredients. While bovine sourced gelatin is popular in the US forsource availability, cost and religious reasons, porcine and/or the morerecently commercially available piscine gelatin sources can be used infull or partial substitution for bovine gelatin as desired. However,especially for those markets that prohibit or disfavor gelatin usage(because of health concerns regarding gelatin, e.g., bovine spongiformencephalopathy) other proteins or even other conventional ingredients,e.g., hydrophilic colloids, can be added to the binder sugar syrup.

[0080] In a particular embodiment, the milk protein is obtained from drymilk powder. See, for example, a description of the binder in commonlyassigned and co-pending U.S. Ser. No. 09/667,209, entitled, “LAYEREDCEREAL BARS AND THEIR METHODS FOR MANUFACTURE” (filed Sep. 21, 2000 byBarrie R. Froseth, et al). If desired, however, protein can be added tothe binder in any suitable amount. Good results are obtained when theprotein ingredient such as gelatin comprises about 1% to about 8% of thebinder

[0081] Although conventional formulations for binder can be used, unlikeconventional cereal bar food products, the food products of the presentinvention require much less binder. In most embodiments, there is morebase than binder, but the invention is not so limited, as conventionallevels of binder can also be used, if desired. In one embodiment, thefood product contains no more than 25% binder. In these embodiments, thesugar binder content is reduced in half compared to otherwise comparableproducts prepared by conventional techniques. In another embodiment, thefood product contains even lower levels of binder, namely about 12.5%binder or less. In yet another embodiment, the food product contains nomore than 10% binder. With respect to the individual ingredients of thebase, in one exemplary embodiment in which there are two dryingredients, with the first dry ingredient being a grain-based productand the second dry ingredient being a dried fruit, the ratio ofgrain-based product to dried fruit to binder is about 20:1:0.5. In otherembodiments there is more or less binder and/or dried fruit, buttypically there will be more grain-based product than either dried fruitor binder. In some embodiments, there can be about the same amount, byweight, of dried fruit and binder, or there can be more binder thandried fruit.

[0082] In one embodiment, the product is fabricated without any binder.In this embodiment, freshly prepared puffed RTE cereal pieces are usedwhile still hot and plastic immediately after puffing, especially cerealpieces prepared by direct expansion from a twin screw extruder. If usedimmediately after puffing and prior to setting (i.e., before cooling tobelow their glass transition temperature through cooling and moistureloss), the puffed RTE cereal pieces posses sufficient tackiness andplasticity to be able to be formed into a composite mass employinglittle or even no binder. In this embodiment, it can be possible to formthe food product by compressing hot RTE cereal pieces immediately afterbeing puffed without the use of any binder or with less than one (1)%binder. This is likely possible due to the residual moisture present inthe puffed cereal pieces, which flashes off immediately after beingpuffed, causing the pieces to be somewhat tacky. It is likely that asthe cereal pieces cool as well as lose the surface moisture, they passthrough glass transition, such that the cooled product is less tacky. Inanother variation, additional dry ingredient (s), such as dried fruit,can be used in addition to puffed RTE cereal pieces, together with lessthan one (1)% binder.

[0083] In one embodiment, the food product further contains a topicalcoating or topping layer. The topping can be a creamy topping, such as afrosting covering a portion or even the entire surface of the foodproduct or a glaze that is drizzled onto the top layer. The toppinglayer can also be any other type of coating made from any of the foodsnoted above. Preferred for use are chocolate coatings, icings andconfectionary fat coatings. In yet another alternative embodiment, dryor powdered ingredients are used as a topping layer either alone or inconjunction with a creamy topping layer. This includes, but is notlimited to, colorings, sugars in various forms (e.g., brown sugar, whitesugar, confectionery sugar, etc.), sugar substitutes, ground or powderedspices (e.g., cinnamon, nutmeg, cardamom, various salts, etc.), herbs,dried whole fruits flavorings and other flavorings as defined herein,which can be added as dried or powdered flavorings, other powderedtoppings (including powdered fruits, milks, milk fractions, juices,cheeses and/or dried cheese powders, meat or fish flavors, tomato orbarbeque flavors, butter, caramel, salt, etc.), aromatic substances,including any type of taste-enhancing additives, and so forth.

[0084] In yet another embodiment, the food product is partially orcompletely enrobed in a coating. The coating can be a liquid coatingthat solidifies at room temperature and is applied by dipping the foodproduct into a heated bath of the coating, such as a chocolate coating.Alternatively, the food product can be submersed into a dry or powderedcoating and rolled around until adequate coverage is obtained. This caninclude, for example, a dusting with cinnamon and sugar, milk powder andsugar, and so forth.

[0085] In one embodiment, the food product further includes any type offilling layer or core portion. In most such embodiments, such a fillinglayer would have a variable thickness with a non-uniform appearancealong the outside edge. In another embodiment, some or all of the layersare twisted within the food product to form a swirled pattern. In yetanother embodiment, the filling is applied in the middle and the productshaped into a log roll. In one embodiment, the filling layer is a driedmilk-filling layer. In another embodiment, the filling layer is any typeof creamy or chunky layer. This can include, but is not limited to, anytype of peanut butter layer, chocolate layer, frosting layer, honeylayer, yogurt layer, gelatin layer, fruit filling layer, including afruit paste layer, and so forth. The filling layer can also be made withany other suitable foods or food combinations, including any type ofadditive. Examples include cereals and cereal pieces, granola pieces,nuggets, nuts, nut pieces, marshmallows, marshmallow bits (marbits),candies, candy pieces, cookies, cookie pieces, chocolates and chocolateproducts, including white and milk chocolates (e.g., chocolate chips,candy bars, etc.), other types of edible particulates (e.g., peanutbutter chips, butterscotch chips, etc.), fruits (whole or pieces), driedfruits (whole or pieces), e.g., coconut, raisins, including freeze-driedfruits, fruit parts, fruit products (e.g., fruit syrups, etc.), and soforth. This can include, but is not limited to, any type of peanutbutter layer, chocolate layer, frosting layer, honey layer, yogurtlayer, gelatin layer, fruit filling layer, fruit paste layer, meatlayer, and so forth. The filling layer can also be made with any of thefoods or food combinations described above for use as a dry cerealingredient or binder. The filling layer can also be any type ofconfectionery filling or compound coating, including the type of milkfilling layer discussed in U.S. Ser. No. 09/667,209, supra.

[0086] Use of milk derived ingredients either in a filling layer or inthe binder or base can add substantially to the nutritional value of thevacuum packagable food product. This can be in the non-fat dry milksolids or “powdered milk”, milk fractions, e.g., whey or whey proteinsolids, and so forth. Such a product could be considereddiabetic-appropriate for class II diabetes, as it would slow the insulinresponse. With the use of vacuum packaging, such a product is shelfstable for up to one year or more.

[0087] The overall water activity of the final product is also aconsideration. It is known that as the A, increases, the cereal textureis negatively impacted, becoming soggy and stale at some specific value,depending on the cereal selected. However, as the A, decreases, thebinder becomes more crystalline and brittle due to the absence of theplasticizing effect of water. Broadly, the present food products canrange in water activity from about 0.2 to about 0.5. At higher values,product shelf life can degrade due to undesirable deterioration of oneor more sensitive ingredients. At very low water activities, one or moreproduct ingredients can exhibit excessive hardness. For example, driedfruit ingredients such as raisins can become too hard as moisturemigrates from the moister raisin to the very dry RTE cereal. Betterresults are obtained when food products are characterized by wateractivities ranging from about 0.3 to about 0.45. It is important to notethat since the RTE cereal base ingredients have water activities ofbelow 0.2, greater proportions of binder or binders having higher wateractivity values can be employed such that the combined products afterequilibration enjoy A_(w) values within the present ranges. For bestresults, the present food products are formulated and prepared to havewater activity values ranging from about 0.3 to 0.4.

[0088] Unlike the components of conventional portable food products, thefood products of the present invention are not crushed or broken duringproduction resulting from the absence of a compression step duringfabrication. Surprisingly, in one embodiment, at least 85% of thefrangible food products remain whole and undamaged. This is particularlyadvantageous for embodiments in which RTE cereal or RTE cerealcombinations comprise one of the dry ingredients. Specifically, most ofthe RTE cereal pieces in the single composite mass remain whole andunbroken, thus maintaining a shape recognizable to the consumer. In oneembodiment, at least 90% of the RTE cereal pieces are whole cerealpieces. It is the whole frangible products that contribute, in part, tothe irregular appearance of the embodiments having uncut surfaces oredges. As a result, although it can be said that the food product has aparticular shape, such as substantially rectangular, the actual shape isa much less defined shaped than conventional cut food products. Forexample, although the food product in FIG. 1 is “substantially”rectangular, the edges of the food product are clearly not substantiallystraight, as in conventional cut food products. Rather, if one were totrace the outline of the food product in FIGS. 1 and 2, it is clear thatthe edges contain primarily curved lines, with multiple bumps andindents, from the irregular placement of the whole cereal pieces alongthe edges. In other words, there is no leading edge or trailing edge tothe food product.

[0089] While not critical per se, an advantage of the present packagedfood products is having an improved crush resistance feature. Due to theclosely interlocked structure of the puffed cereal pieces, the productsexhibit a surprising resistance to crushing compared to loosely packedequivalent RTE cereals. Packaged food products herein can be preparedthat exhibit a crush resistance of up to 90 KPa before exhibitingcrushing or deformation. Conveniently, the vacuum package providesstructure and break resistance to the food piece such that aconventional “U” board or other support layer is not required herein.

[0090] The food bars of the present invention are designed to bepackaged in a vacuum package that is an active package that serves notonly to form the food product, but also helps to preserve freshness. Theuse of vacuum packaging also allows for less binder to be used, ascompared with conventional cereal bars, yet, still maintain a barintegrity without falling apart. The resulting product maintains itsfull color, texture and flavor, yet is not overly sweet, as in mostembodiments, the binder comprises less than 25%, by weight, of theproduct. Of course, if desired, vacuum packaged food bars products ofthe present invention can be prepared with higher levels of binder,e.g., up to 65% binder, yet still at least enjoy the extended shelfstability, crush resistance and other advantages of the presentinvention. For example, bar product having high binder levels andcomprising oxygen sensitive ingredients such as freeze dried fruits ordried cranberry pieces can enjoy the shelf stability advantages even ifhigh in sweetness due to high binder levels.

[0091]FIG. 2B depicts one embodiment of an intermediate or uncured foodpiece 200, as it appears prior to being packaged (See FIGS. 3A and 3B).Although the components are identical to those found in the cured foodpiece 100 described above, the uncured food piece 200 is less compactthan the cured food piece 100. In one embodiment, the uncured food piece200 is about 5 to 20% larger in size as compared with the same amount ofa cured food piece 100. The uncured food piece 200 is also warmer intemperature than the cured food piece 100, i.e., 35 to 100° C. As aresult, the components of the uncured food piece 200 are not yet atequilibrium. Specifically, the individual water activity of the variouscomponents are still intact, namely the relatively higher water activityof the binder (not shown) and the lower water activity of the base,since the components have not equilibrated at one overall wateractivity.

[0092] Method of Making Vacuum Packagable Food Product

[0093] The present invention further provides methods for making vacuumpackaged food products comprising, in one embodiment, mixing a settablebinder with a quantity of one or more particulate dry ingredients toform a workable composite mass or mixture; and vacuum packaging aquantity of workable composite mass in a package at least a potion ofwhich is fabricated from a flexible film to thereby form the mass into ashape, and allowing the composite mass to cure to form a vacuum packagedfood product in the form of a single shaped piece. In one embodiment,the food product is vacuum packaged by first subdividing the workablecomposite mass to form measured quantities and then placing a measuredquantity into a package, applying a vacuum to the package, sealing thepackage, and allowing the food product to cure. With the active packageof the present invention, the packaging essentially forms and holds thequantity of pre-cured mass into a shape until the binder cures, e.g.,moisture equilibration and/or cooling, to form a product that retainsthis shape. Additionally, the use of vacuum packaging allows productscontaining even highly oxygen-sensitive components to be shelf stablefor at least 3 months up to about 12 months.

[0094] Binder Preparation

[0095] The binder can be prepared in a binder preparation sub-stepaccording to any binder technique known in the art whether batch,semi-batch, continuous or mixtures thereof. In an exemplary embodiment,the binder is comprised of a sugar syrup, which can be made according toany means known in the art. Typically, such binders are prepared byadmixing wet and dry ingredients and heating to dissolve the dryingredients and cooking, if required, to remove added moisture toprovide sugar binder syrups of desired solids concentrations and wateractivity values.

[0096] Food Product Preparation

[0097] In most embodiments, the food products of the present inventionare produced by combining binder 302 (prepared in a binder use kettle322) with one or more dry ingredients, i.e., “base” 304 to produce aworkable composite mass 305 as shown in FIG. 3A. In this embodiment, thebase 304 is comprised of the primary base ingredient 102, such as puffedO-shaped RTE cereal pieces, and the secondary base ingredient 104, suchas freeze-dried fruit, discussed herein, although the invention is notso limited.

[0098] Bulk amounts of each of the dry ingredients are typically placedin their respective tote dumpers. In the embodiment shown in FIG. 3A,the primary base ingredient 102 is located in a cereal tote dumper 314and the secondary base ingredient 104 is located in a dried fruit totedumper 316.

[0099] The dry ingredients of the base exit the dumper 314 andeventually fall into a hopper 318 located above a mixer 320. In oneembodiment, a constant speed screw is located in the bottom of thehopper to keep the flow constant rather than cyclical, therebymaintaining a constant ratio between binder and base. In one embodiment,the dry ingredients of the base are first dumped onto one or moresecondary conveyors prior to entering the mixer, such as cleatedinclined belt conveyors.

[0100] The binder 302 can be added in any suitable manner to the mixer320. In one embodiment the binder is pumped out of the binder use kettle322 at an elevated temperature, with a binder pump into a binderapplication manifold (not shown).

[0101] The base, i.e., primary and secondary dry ingredients 102 and104, respectively, and binder 302 are combined in the mixer 320 for asuitable period of time to provide an homogenous well blended mixture ofbinder smoothly coating the surface of the various particulates. In someembodiments, other ingredients, such as any of the ingredients describedabove, including reground material, larger particulates, clusters (morethan one dry ingredient adhered together), and so forth, follow the samepath to the mixer in the same manner described above for the dryingredients.

[0102] The temperature of the binder 302 decreases only modestly as itflows through the manifold. In one embodiment, the binder enters themanifold at a temperature of about 54° C. (130° F.). In one embodiment,the binder exits the manifold at a temperature of about 52° C. (about125° F.). In another embodiment, the binder has a temperature of about49° C. (about 120° F.) as it combines with the dry ingredients. However,in embodiments not using protein it is possible to use highertemperatures, since there is no concern re protein degradation causingoff-flavors to develop. In some instances, higher temperature can beneeded to keep the binder from reaching its glass transition temperatureand becoming prematurely cured or hardened.

[0103] In preferred embodiments, the binder 302 and dry ingredients (102and 104) are combined in a ratio such that there is generally lessbinder than base, and in most embodiments there is only about 25%binder, by weight, as compared with the base. In other embodiments, thebinder to base ratio is about 1:1 as is known in the art. In embodimentsin which there are two dry ingredients in the base 304, as in FIG. 3A,e.g., primary and secondary base ingredients, 102 and 104, respectively,the ratio of the binder to primary base ingredient (e.g., RTE cereal) tosecondary base ingredient (e.g., dried fruit) can range from about1:5:0.5 to 1:10:1. In this embodiment, the resulting mixture has atemperature of about 32 to 38 ° C (about 90 to 100 ° F).

[0104] In an alternative embodiment, an enrober is used instead of amixer. In such an embodiment, the base is coated with the binder in theenrober, and then processed in the same manner as discussed below.

[0105] The composite mass 305 then exits the mixer 320 still in the formof a plastic workable, typically warm, composite mass of looselyagglomerated particles of the various base ingredients, and enters thevacuum packaging apparatus 301 (shown in FIG. 3B) directly from themixer 302, with the package-forming process itself providing the shapingmeans for the mass 305.

[0106] In an alternative embodiment, after exiting the mixer 302, theworkable composite mass 305 passes through a means for applyingcompression that provides minimal compression to the mass prior toentering the vacuum packaging apparatus 301. In one embodiment, themixture is compressed due to an opening in the mixer that is sized tocause slight compression of the mass, e.g., a funnel. In anotherembodiment, the workable composite mass passes through one or morecompression rollers arranged to provide minimal pressure. In mostembodiments, the compression applied is sufficient to provide no greaterthan about 10 to 20% compaction in volume, in order or minimize breakageof the frangible food ingredients. However, it is possible to havecompression up to about 40% in some embodiments.

[0107] In most embodiments, the process has the advantage of producingminimal waste since there are no trim pieces due to cutting. This canresult in significant savings as compared to conventional processes thatrequire cutting, as such trim losses alone can approach 12% or more. Inone embodiment, the workable composite mass 305 can optionally passthrough a cinnamon duster where a topical flavoring cinnamon/sugar(1-10:100) mixture is applied.

[0108] Vacuum Packaging Step

[0109] Referring now to FIG. 3B, the workable composite mass 305 can bepackaged by first subdividing it into desired portions by any suitablemeans. In the embodiment shown in FIG. 3B, the workable composite mass305 is divided into a desired portion that is substantially the samesize as the uncured food piece 200 described above in FIG. 2B. Again,the subdividing or separating means will, in most embodiments, notresult in straight, knife-cut edges. The subdividing means should bedesigned to cause a minimal amount of impact or damage to the product,such that most or nearly all of the frangible dry ingredients of thebase remain intact, i.e., whole and not crushed. In the embodiment shownin FIG. 3B, a wire cutter 332 is used, although the invention is not solimited. In another embodiment, a rotary valve is used to process themass, such that after a given amount of the workable composite mass ismoved through, the valve closes, causing the given amount to drop intothe packaging device. In another embodiment, roll extruders togetherwith a wire cutter are used. In yet another embodiment, subdividedamounts are dropped onto a moving sheet or conveyor and a vacuum ispulled each one. In yet other embodiments, ultrasonics can be used tosubdivide the workable composite mass into sized and roughly shapedamounts. In yet another embodiment, the workable composite mass 305 ispumped into a chamber having a piston designed to dump the contents ofthe chamber into an individual package. In less preferred embodiments,the workable mass is formed into continuous sheets that are cut intoribbons by conventional rotary knifes or sonic cutters to form ribbonsthat are in turn subdivided into individually shaped and sized portionsof composite food mass. Such an embodiment can include any suitablemeans for subdividing the portions, including a wire, ultrasonics, andso forth. The desired portions are typically determined according toweight, such that individual servings of the desired weight, asdescribed above, are created

[0110] Regardless of how individual portions are prepared, the presentmethods of preparation can further include the step of packaging theindividual portions of quantities into vacuum packaging that forms theworkable portions of the composite mass into a desired shape. Inpreferred form, the products are in the form of a food bar disposedwithin a vacuum package or pouch fabricated from flexible packagingmaterial such as packaging film. The vacuum package or pouch can befabricated using any suitable type of packaging device. In theembodiment shown in FIG. 3B, a packaging device similar to the deviceused to create a vertical form filled and sealed (VFFS) packagedescribed in U.S. Pat. No. 5,171,950 to Brauner et al, entitled,“FLEXIBLE POUCH AND PAPER BAG COMBINATION FOR USE IN THE MICROWAVEPOPPING OF POPCORN,” (issued Dec. 15, 1992), commonly assigned andincorporated herein by reference, is used, although the invention is notso limited. However, unlike a traditional VFFS package made ofbreathable high density polyethylene, the packages of the presentinvention are made with materials designed to hold a vacuum.

[0111] Any suitable type of vacuum food packaging can be used. In oneembodiment, the packaging includes at least a portion that is flexiblesuch as to engage the workable food mass and confine that mass into adesired shape during the curing step. In a preferred embodiment, any ofthe vacuum packaging means and packaging materials of PACKAGE ANDMETHOD, supra, is used to provide a package in the form of a flexiblefilm pouch. For example, a vacuum tube and nozzle can be removablycoupled to the pouch. A vacuum is drawn on the pouch and the pouch isheat sealed. Good results are obtained when the sealed pouch has avacuum of 50 millibar or less, and for better results, less than 15millibar. In other variations, the pouch can have a lower vacuum bypartially back flushing the pouch with a controlled low oxygenatmosphere up to 150 millibar of nitrous oxide, argon, neon or mixturesthereof. Such vacuum packages provide sufficient compression to thecomposite food mass to hold the mass in shaped form until the bindersets to cure the mass into the desired end product form.

[0112] In the embodiment shown in FIG. 3B, a continuous roll stock 334of flexible heat sealable laminated film packaging material is provided,such as a double layer of material, thus providing inner and outerlayers with a thermoplastic sealing layer and intermediate adhesivelayers. For example, the inner layer can additionally include a releaseagent to facilitate removal of a food bar from the package that includedparticularly sticky ingredients. The packaging film can of courseinclude additional layers or layer properties in known manner, e.g.,metallization, to improve one or more package properties, e.g.,reductions in gas permeability.

[0113] The forming horn 338 is shown in FIG. 3B in block form. As can beunderstood from this view, the roll stock 334 is folded into an envelopeor rough-like configuration 336A as it is being drawn from its rolledcondition. The marginal portions of the roll stock 334 are urged intoengagement and heated by a vertically oriented sealer 340 to form a lapor fin seal or seam 340A along an edge of the envelope 336A. There is anupper horizontal or transverse sealer 342 in this embodiment that formsa seal 342A that seals the bottom of the envelope 336A. Additionally, alower horizontal or transverse sealer 344 forms an upper seal 344A toseal the upper end of a subsequent envelope. Just prior to, or inconjunction with creating the upper seal 344A in the subsequentenvelope, the vacuum 345 is applied. After the upper seal 344A isformed, the resulting pouch 336 is separated from the preceding envelope336A with a cutter 346 as shown.

[0114] A food feed funnel 348 can be used to deliver a measured quantityor supply of the workable composite mass 305, e.g., the uncured foodpiece 200, into the envelope or trough 336A that results in thecompleted pouch 336. In another embodiment, the funnel is replaced witha substantially straight cylinder or tube. In yet another embodiment,the funnel is divided longitudinally to accommodate additional and/orseparate ingredients, in order to provide an alternative appearanceand/or flavoring/texture to the final product. Continuing with theprocess of FIG. 3B, the flow of the uncured food piece 200 is downwardlyas indicated by arrow 350. After sealing by the sealers 340, 342 and344, the abovementioned severance by the cutter 346 enables thecompleted pouch 336 to fall gravitationally onto a conveyor 352 locatedbelow, the directional movement of the completed pouches 336 indicatedby arrow 356. In one embodiment, not shown, the package can additionallycomprise a support layer such as a conventional support “U” board (notshown).

[0115] The pouch 336 is an active package that, as FIG. 3B shows, isform-creating and form-fitting, essentially creating, as well asmaintaining, the product shape of the contents within. In this instance,“bumps” 354 from the plurality of frangible pieces that compriseprimarily the primary base ingredient 102 are contained within the pouch336 can clearly be seen. In some embodiments, the bumps 354 can be aresult of both the primary and secondary base ingredients 102 and 104,respectively. The resulting package or pouch 336 is surprisingly strongand puncture resistant. As can be seen, such a vacuum process asdescribed herein, produces a relatively tight active package, whichnecessarily means a significantly stronger package as compared withconventional loose-fitting passive packages.

[0116] In another embodiment, a vacuum chamber can be used during thepackaging process, such that the entire packaging process takes placewithin the chamber.

[0117] The resulting vacuum-packaged food products are allowed to coolnaturally in most embodiments or can be cooled by cooling means toaccelerate curing. As the product cools, the uncured food piece 200 istransformed rapidly over a short cure or cooling time to form the curedfood piece 100 shown in FIGS. 1 and 2A. In one embodiment, the uncuredfood piece 200 cures to a cured food piece 100 in about 4 minutes to 48hours, depending on several factors, including, product content,temperature, and the like. Specifically, the uncured food piece 200 isformed by the active packaging process to any suitable size and shape.In one embodiment, the resulting cured food piece has a dimension ofabout 50 to 130 mm (about 0.25 to 0.5 in). Following curing with theactive packaging, the density of the dry ingredient base is alsoincreased. In one embodiment, the bulk density of the dry ingredientbase after compression is about 1.1 to 1.4 times the bulk density of thedry ingredient base before curing. In a preferred embodiment, the bulkdensity after compression is about 1.1 to 1.2 times the bulk density ofthe dry ingredient base before curing. In other words, the compressiondue to the active packaging is preferably in the range of about 10 to20%. In an exemplary embodiment, the dry ingredient base has a bulkdensity of about 1.2 g/cc before curing and a bulk density after curingof about 1.3 to 1.7 g/cc.

[0118] Any of the aforementioned commercial devices described in eitherFIG. 3A or FIG. 3B can include a system controller, as is known in theart. It will also be understood by those skilled in the art that theapparatus for manufacturing the food products includes all knownapparatus for moving components into, through and out of a foodprocessing system. This includes, but is not limited to, various typesof pumps, filters, strainers (such as magnetic strainers, decline dualstrainers, etc.), flow meters, heat exchangers (such as plate type sweptsurface heat exchangers), drains, level indicators, grate magnets, andso forth. (A grate magnet is essentially a series of parallel magneticbars placed in an ingredient or product stream to remove magnetic metalparticles from the stream as a consumer protection measure). Further,although in many instances only the term “kettle” has been used herein,it is to be understood that in some embodiments there are separatekettles for mixing versus holding, i.e., using. It will further beunderstood by those skilled in the art that all of the lines in thesystem are made from materials that can be either flexible or rigid,depending on their location and use. Furthermore, all lines are of asuitable diameter for their intended purpose, but are preferably betweenabout 1.3 cm (0.5 in) and about ten (10) cm (four (4) in). in diameter.It will also be appreciated by those skilled in the art that flexiblelines can include hoses made from rubber, plastic or other suitablematerial, and rigid lines can be made from galvanized metal, stainlesssteel, copper, PVC or other suitable material.

[0119] A block diagram of one embodiment for producing vacuum packagedfood products is shown in FIG. 4. The process 400 begins by preparing402 a workable composite mass containing a grain-based food ingredientand a low water activity binder and placing 404 a quantity of theworkable composite mass into a flexible packaging envelope. The processcontinues by applying 406 a vacuum to the flexible packaging envelopeand sealing 408 the flexible packaging envelope to form a flexiblesealed package. The process concludes by allowing 410 the workablecomposite mass to cure within the flexible sealed package to form avacuum packaged food product. The product can further be subdivided intodesired portions prior to packaging. There is minimal product waste inthe process of the present invention, as there is no trimming steprequired.

[0120] In the preferred embodiment, the final products of the presentinvention are generally less sweet than conventional cereal bars,primarily because less binder is used. In most embodiments, the bindercomprises less than 35%, by weight, or even 25% or less of the product.In many embodiments, the product also has a lighter texture as comparedwith conventional cereal bars, due to the efficient compaction of thevacuum packaging.

[0121] Prior to opening and consumption, the vacuum packaging provides apreserved freshness appearance and value. Overall, upon opening thepackage, surprisingly, the food product is in the form of a single piecesuch as bar that retains its bar form notwithstanding, in the preferredembodiments, the low binder levels employed. Unlike certain known barproducts, the bars are perceived as being relatively dry, i.e., are notsticky, so are readily removable from their package. Those food productsthat comprise humectants can be chewy from the presence of the binder aswell as any chewy dry ingredient and the effects of any humectants. Inmost embodiments, including those that use RTE cereal pieces, the foodproduct will also have a highly desirable crispy texture due to the useof a frangible food ingredient. Additionally, the food products exhibita surprisingly pleasing appearance resulting from the piece integrity ofa large fraction the frangible ingredients remaining whole. The productsexhibit superior product stability as indicated by low hexanal values.

[0122] Although the food product has been described primarily in termsof a handheld product containing RTE cereal pieces, it should beunderstood that virtually any type of dry ingredients can be combinedand packaged as described herein, including various types of crackers,pretzels, grain-based chips, popcorn and so forth. In one embodiment,the food product is a savory seasoned snack. In other embodiments, thefood product can be formed around one or more sticks or handles, so thatthe consumer can avoid touching the product, if desired, without use ofan external material such as the torn packaging, napkin and so forth. Inyet another embodiment, the food product can be a controlled portionedanimal food, such as an animal treat.

[0123] Unlike some conventional cereal bars, the food products of thepresent invention are not baked, but are non-cooked food products formedfrom pieces of identifiable grain-based ingredients pressed togetherwith other components and delivered with minimal, if any, damage.

[0124] Although specific embodiments have been illustrated and describedherein, it will be appreciated by those of ordinary skill in the artthat any arrangement that is calculated to achieve the same purpose canbe substituted for the specific embodiments shown. This application isintended to cover any adaptations or variations of the invention. It isintended that this invention be limited only by the following claims,and the full scope of equivalents thereof.

What is claimed is:
 1. A packaged food article, comprising: a packagemaintaining at least a partial vacuum, wherein at least a portion of thepackage is flexible; and at least one food piece disposed therein in theform of a shaped solid composite mass comprising an aggregate basehaving a quantity of food particles, wherein at least a portion of thefood piece is in conforming contact with the flexible package portionand wherein the food piece has a water activity of 0.45 or less.
 2. Thepackaged food article of claim 1 further comprising a binder.
 3. Thepackaged food article of claim 2 wherein the binder comprises less than25%, by weight, of the package. 4 The packaged food article of claim 2wherein the binder comprises less than 10%, by weight, of the package.5. The packaged food article of claim 3 wherein the food piece has awater activity ranging from about 0.15 to about 0.45.
 6. The packagedfood article of claim 3 wherein the binder is a sugar-protein binder. 7.The package of claim 2 having an internal pressure of less than about150 millibars.
 8. The package of claim 2 having a crush resistance of upto about 90 kPa.
 9. The package of claim 2 containing less than 1 ppm ofhexanal for at least 3 months. 10 The package of claim 1 wherein thequantity of food particles includes a grain-based frangible foodingredient comprising a plurality of frangible pieces and the basefurther comprises a second dry ingredient.
 11. The packaged food articleof claim 10 wherein the plurality of frangible pieces are RTE cerealpieces.
 12. The packaged food article of claim 10 wherein the pluralityof frangible pieces are selected from the group consisting of chips,pretzels, crackers, and mixtures thereof.
 13. The packaged food articleof claim 10 wherein 90% or more of the plurality of frangible pieces areunbroken.
 14. The packaged food article of claim 10 wherein at least aportion of the second dry ingredient includes a highly oxygen sensitiveingredient.
 15. The packaged food article of claim 14 wherein the highlyoxygen sensitive ingredient is fruit or dried fruit.
 16. The packagedfood article of claim 15 wherein the fruit and dried fruit are selectedfrom the group consisting of cranberries, raisins, prunes, strawberries,raspberries, blueberries, cherries, pineapple, mangoes, apricots,bananas, apples, kiwi, peaches, tangerines, oranges and mixturesthereof.
 17. The packaged food article of claim 15 wherein the driedfruit is freeze dried fruit.
 18. The packaged food article of claim 2wherein the package is made from a film having an oxygen barrier and amoisture barrier.
 19. The packaged food article of claim 18 wherein thefilm is laminated.
 20. The packaged food article of claim 19 wherein thepackage is puncture resistant.
 21. The packaged food article of claim 18wherein the package is translucent, opaque or clear.
 22. The packagedfood article of claim 2 wherein the composite mass has no cut surfaces.23. The packaged food article of claim 18 wherein the food piece isfortified with vitamins or minerals.
 24. The packaged food article ofclaim 23 wherein one of the minerals is calcium.
 25. The packaged foodarticle of claim 24 wherein the calcium is provided by calciumingredients having a particle size of less than about 20 microns. 26.The packaged food article of claim 25 wherein the calcium is comprisedof particles having a particle size of less than about five (5) microns.27. The packaged food article of claim 2 wherein the food piece includesabout 1% to about 40% by weight of a second dry food ingredient selectedfrom the group consisting of dried fruit pieces, nuts, nut pieces,marshmallows, marshmallow bits, dried marshmallows, candies, candypieces, cookies, cookie pieces, chocolates and chocolate products,including white and milk chocolates, peanut butter chips andbutterscotch chips, and raisins and mixtures thereof.
 28. The packagedfood article of claim 2 wherein the composite mass has less than about0.5%, by weight, of one or more humectants.
 29. The packaged foodarticle of claim 28 wherein the humectants include polyhydric alcohol.30. The packaged food article of claim 29 wherein the polyhydric alcoholis glycerol or sorbitol.
 31. The packaged food article of claim 2wherein the composite mass is substantially free of humectants.
 32. Thepackaged food article of claim 2 wherein the composite mass is cured.33. The packaged food article of claim 32 wherein the composite mass hasa water activity of between about 0.2 to 0.5.
 34. The packaged foodarticle of claim 32 wherein the package is an active package that formsthe composite mass into a final shape.
 35. The packaged food article ofclaim 34 wherein the final shape is a substantially rectangular shape.36. The packaged food article of claim 34 wherein the final shape is asubstantially log shape or circular shape.
 37. The packaged food articleof claim 34 wherein the final shape is a complex shape.
 38. The packagedfood article of claim 37 wherein the complex shape is selected from agroup consisting of regular geometric shapes, patterned irregular shapesand unpatterned irregular shapes.
 39. The packaged food article of claim2 wherein the composite mass is uncured.
 40. The packaged food articleof claim 39 wherein the temperature of the composite mass is above aglass transition temperature of the binder.
 41. A food productcomprising: a base having RTE cereal pieces, wherein most of the RTEcereal pieces are whole cereal pieces; a binder adapted to hold the basetogether to form a workable composite mass, wherein the binder comprisesless than 25%, by weight, of the product, and the workable compositemass is vacuum packaged in a package.
 42. The food product of claim 41wherein at least 90% of the RTE cereal pieces are whole cereal pieces.43. The food product of claim 41 wherein at least 99% of the RTE cerealpieces are whole cereal pieces.
 44. The food product of claim 41 whereinthe RTE cereal pieces are selected from the group consisting of o-rings,flakes, shreds, biscuits, rings, spheres, squares, rounds, triangles,convex-shapes, hexagonals, tubes, bugles, oblongs, pillows and mixturesthereof.
 45. The food product of claim 41 wherein the product has no cutsurfaces.
 46. The food product of claim 41 further comprising fruit ordried fruit.
 47. The food product of claim 46 wherein the dried fruit isfreeze-dried.
 48. The food product of claim 46 wherein the fruit ordried fruit retains a fresh smell for at least 3 months.
 49. The foodproduct of claim 41 wherein release additives are included in the foodproduct.
 50. The food product of claim 49 wherein the release additivesare selected from the group consisting of cheese, peanut butter and meatpaste.
 51. The food product of claim 41 wherein the food product is asavory seasoned snack.
 52. The food product of claim 41 wherein the foodproduct further comprises a stick embedded in the food product forholding the food product.
 53. The food product of claim 41 furthercomprising a coating.
 54. The food product of claim 41 furthercomprising a filling.
 55. The food product of claim 41 wherein thebinder is swirled together with the RTE cereal pieces.
 56. The foodproduct of claim 41 wherein the food product contains fluid milk orpowdered milk.
 57. The food product of claim 41 wherein the food productis shelf stable for at least 3 months.
 58. A method of forming a vacuumpackaged food product comprising: preparing a workable composite masscontaining a grain-based food ingredient and a low water activitybinder; placing a quantity of the workable composite mass into aflexible packaging material; applying a vacuum to the flexible packagingmaterial; sealing the flexible packaging material to form a flexiblesealed package; and allowing the workable composite mass to cure withinthe flexible sealed package to form a vacuum packaged food product. 59.The method of claim 58 wherein the composite mass cures within about 4minutes to 48 hours.
 60. The method of claim 58 wherein the grain-basedfood ingredient is a frangible ingredient.
 61. The method of claim 58wherein the composite mass is subdivided prior to being placed into thepackage.
 62. The method of claim 61 wherein the composite mass issubdivided with a wire cutter.
 63. The method of claim 61 wherein avacuum of 50 millibar or less is applied to the package.
 64. The methodof claim 58 wherein the composite mass comprises less than 25% binder,by weight.
 65. The method of claim 64 wherein the food product containsone or more highly oxygen sensitive ingredients.
 66. The method of claim65 wherein the one or more highly oxygen sensitive ingredients is fruitor dried fruit.